Saturday 29 April 2017

Bonnet Catches

Next job of the day was the bonnet catches. Took quite a while to get them lined up and measured correctly. Now they are on, the bonnet fits nicely and feels much more solid.


Fuel sender

A quick job to start the day, I added the fuel sender.  using the provided gasket and screws I tightened it in place ensuring the float was free moving inside the tank. I also made and added a second earthing point as required by the IVA.


Friday 21 April 2017

Shortened Oil filter

Just a quick job which was to change the oil filter. Was a case of removing the old one and putting the new one in.

Taking the old one off wasnt easy as it had stuck in place, not having an oil filter removal tool, I punched a screwdriver through the side and used that as leverage to loosen it. New one in place and lots more clearance now.



Engine mods

After much worrying and putting it off, today was the day to start the engine. It needs a number of modifications as the car is tiny compared to what the engine normally goes in and the ground clearance is much less.  I started with the sump.  Ive bought a new lowered sump from GBS and it gives quite a bit more ground clearance so when going over raised manhole covered and speed bumps it doesnt rip the sump off.

So first thing was to get the current oil out. Not an easy job, but again not overly hard, just awkward as I had it on a rolling set of wooden pallets. Anyway, once that was empty, I laid the engine on its side and removed the air intake / fuel manifold.




Just a few bolts so nice and easy. I then covered the area with tissue and stuck it in place with a bit of tape.

Next up was to remove the sump. Its in 2 parts, an aluminium part and a steel part. First i had to remove the steel part which allowed access to the oil pick up pipe which I then removed before taking the aluminium part off. This was where the new sump would now fit.  I added the new pick up pipe and then dry fitted the sump.  Some of the screw holes were slightly off so widened them with a file before a final dry fit.


Next up (no photos) but I added some gasket sealant around the new sump and added the cork gasket.  I held it in place with the bolts and then added a layer around the top of the cork gasket before fitting it to the engine. I bolted it all up and admired my work.


Thursday 20 April 2017

Second top tunnel covered

Ended up with another spare 10 mins this afternoon so covered the second top tunnel panel with the green "leather" I've bought. I covered the cut out sections with some IVA trim to help protect the cables that run through the holes.

Only one left to do, but will wait until the gearbox is in so I know where to cut for the gear lever.



Fog light testing

After yesterdays success with the electrics, I was gutted the fog light didn't work. After some fault finding, it turns out it was because I didn't have a bulb!! I ordered some of amazon with next day delivery so rushed out to test them as soon as they arrived.

Worked perfectly, and to my surprise, the fog light switch illuminated a nice shade of blue too.




Wednesday 19 April 2017

First electrics test - Video

First electrics test video

Amazing afternoon on the car

So this afternoon I got about 2 hours outside and achieved amazing results. All i really wanted was to get the horn working and my end goal for the easter period was to finish the whole cockpit.

So, connected it all up and put the dash in for the visual effect. Connected the battery and then just sort of hoped things would work - It did.

Tested the following:
Headlights
Side lights
Main beam
Horn
Rear fog light (didn't work and after some fault finding, turns out I didn't have a bulb)
wipers
Washer jets
Clocks all light up and do their sweep test
Speedo reads a speed when pushing the car
Brake lights
Handbrake warning
Number plate light

Possibly some others. Either way, really chuffed with todays achievements.




Sunday 16 April 2017

Centre Tunnel panels


After being rained off this morning, I spent an hour in the shed this evening and covered one of the top tunnel panels in leatherette ready for fitting. 

Looks good and now need to ensure the rest match. 


More carpets

Easter Sunday and I got a few hours outside so tried to finish the carpets. Ive moved away from impact adhesive and tried B&Qs cheap "grab adhesive". It gave me enough time to move the carpet around before setting solid and only £2.50 a tube. Very impressed.

Anyway, cracked on and got the passenger side finished, some of the boot and some of the drivers side. Everything is now trimmed and ready to go but got caught in a heavy Easter shower so called it a day.




Friday 14 April 2017

Carpets


First job of the day was a few carpets. I quickly ran out of glue though so moved onto electrics. I fitted the big panel which sits behind the seats and a few other smaller bits. Makes a massive difference when its carpeted.



Wiring


Following GBS's wiring diagram, I made a number of connections today. The speedo sensor, low pressure fuel pump, ignition and a few others. All are the same as the other electrical connections and use spade connectors in a connection block. should be able to start testing the electrics soon.



Horn, speedo sensor and tunnel panel


A few little jobs today, lots of work and not a lot to show but all needs doing.

First was to fit the horn, straight forwards job of drilling a hole, fitting a rivnut and connecting up the wiring harness.



Next was the speedo sensor, this needs to sit 1-2mm above the heads of the bolts which attach the propshaft to the diff. As the bolts pass they create a magnetic current which is interpreted by the speedo and shows the speed of the car. Quite difficult to get lined up as its a tight space but overall an easy job.



Final job now the sensor and bracket were in, was to attach the drivers side tunnel panel. Same as the other side, but this was all predrilled and ready to go so simply ran a bead of sealant and riveted in place.


Battery fitted and cables attached

The car is now alive!!!!

It has power so will soon be able to start testing some of the functions I've got connected up. Battery was easy, just dropped into the holder I fitted a while ago and then held in place with the strap.  I drilled two holes in the firewall and lined them with rubber gaskets which I fed the cables through. Positive to the fusebox and negative to the chassis. 




Clocks fitted

Frustratingly quick job considering the cost.  Fitting the clocks was as easy as placing them in the holes id drilled months ago and tightening up the screw on the rear. I then connected the cables and fitted to the car. Easy job, makes a massive difference......